Adjustable mold for concrete median barrier

ABSTRACT

An adjustable mold for casting asymmetric concrete highway divider sections includes a fixed sidewall, a movable sidewall, and two end walls. Each of the end walls is divided vertically into a first fixed panel and a second adjustable panel. The old can be set up to produce a barrier section that accommodates any difference in grade levels between the separated roadway lanes, within a preselected range, by adjusting the height of each second end panel relative to the adjacent first end panel and by adjusting the height of the movable sidewall to match the second end panels. All adjustments are made by means of simple jack screws. The end walls and the movable sidewall are mounted on hinged frames that can be swung open to facilitate removing a section casting from the mold.

BACKGROUND OF THE INVENTION

The present invention relates to a mold for casting a concrete medianbarrier, and particularly to a mold which can be adjusted to produceselectively different asymmetrical barrier sections conforming todifferent grade levels of two adjacent roadway lanes.

Modern highway concrete median barriers have a specified profile thathas been scientifically developed to receive and contain a travellingvehicle that strikes the barrier, to avoid reflecting the vehicle intoadjacent lanes of traffic. As shown in FIGS. 1-3, a barrier 1 of thistype has a profile that includes at least one upwardly inward slopingface with two slopes 3, 4, connecting a lower vertical surface 5 and anupper vertical surface 6. The sloping face intersects the lower verticalsurface at a level which must be approximately three inches above thesurface of an adjacent roadway lane 7 (FIG. 1). Normally, such barriersare symmetrical, having identical profiles on opposite sides, as shownin FIG. 2, resulting in a stable barrier in which the width of the base9 is several times greater than the width of the top 10. In situationswhere the roadway lanes 7, 8 on each side of the barrier are atdifferent levels, however, the barrier must be asymmetric with respectto the vertical center plane of the barrier, so that the slopingportions on the two sides commence at the required three inch heightabove the respective lane surfaces, as shown in FIGS. 1 and 3 where thecorresponding portions of the shifted side are identified by the samenumerals with a prime. Since the difference in grade between the lanesmay vary over the standard 20-foot length of a barrier section, one sideprofile often must be skewed as well as translated in a vertical planewith respect to the other side profile.

Although it is standard practice to prefabricate standard symmetricmedian barrier sections under factory controlled conditions, asymmetricbarrier sections have had to be cast at the job site in moldsspecifically set up for each secton. This procedure is expensive andslow; it interferes with other work on the job; and it does not resultin the quality of product obtainable at a factory location.

A method and mobile apparatus have been developed (see U.S. Pat. Nos.3,792,133 and 4,014,633 of Goughnour) for continuously slip castingasymmetrical median barrier walls directly in place on a highway underconstruction. The apparatus includes a screed having two sidewalls, atleast one of the sidewalls being vertically adjustable relative to theother to accommodate variations in grade level of the roadways on theopposite sides of the barrier. This system eliminates the labor neededto set up and take down formwork for successive barrier sections, butthe procedure requires close coordination of several different crewspreparing the roadbed, setting the reinforcing steel, moving andadjusting the form, and pouring and settling the concrete. The concretemix used in this process must by "dry" enough to be accurately extrudedfrom the mold but must also be wet enough to be extruded and wet enoughto retain entrained air in the mixture (for durability). Such an optimummixture is difficult to obtain consistently under job site conditions.In addition, the quality of the concrete mix used at a job site cannotbe controlled as closely as is possible at a factory site.

Various types of adjustable forms for concrete structures are known, forexample for U.S. Pat. Nos. 1,644,587 of Heltzel, 3,071,833 of Tumey,1,214,870 of Zeiser, 2,610,381 of Rosati et al., 3,704,852 of Wellander,1,743,965 of Moore, 955,282 of Pocock, and 1,586,352 of Cochran. Each ofthese prior art mold apparatuses is adapted to solve a specific moldingproblem, and only the form of Tumey is specifically intended for use inprefabricating a concrete member, as opposed to on-site fabrication.None of them solves the problems involved in providing a reusable, fullyadjustable mold for prefabricating asymmetric mediam barriers.

SUMMARY OF THE INVENTION

The object of the present invention is to provide a reusable adjustablemold apparatus for casting concrete highway median barrier sections, themold being capable of producing standard length barrier sections, eithersymmetric or asymmetric, within the full range of vertical differencesencountered in practice between roadway grades on the two sides of thebarrier.

A further object of the invention is to provide an adjustable mold forhighway median barrier section that is easy and quick to set up.

Another object of the invention is to provide an adjustable mold thatpermits rapid extraction of a cured concrete barrier section.

Another object of the invention is to provide an adjustable mold that isrigid enough to maintain close dimensional tolerances for the finishedproduct.

Still another object of the invention is to provide a fully adjustablemold for concrete median barrier sections that provides a product ofsuperior quality that requires little or no further finishing afterextraction from the mold.

The above and other objects are provided by a reusable adjustable moldfor highway median barrier sections capable of accommodating acontinuously variable vertical difference of up to two feet between thetwo side profiles and from end to end of a standard 20-foot barriersection.

The mold includes first and second elongated side walls, an elongatedrectangular base wall, and first and second end closures. The first sidewall is fixed in a level and upright position, and one longitudinal edgeof the base wall is fixedly attached adjacent to the bottom edge of thefirst side wall. The second side wall is slidably supported on verticalrails of an upright side framework that is pivotally mounted to swing(about a horizontal axis that is parallel to the longitudinal axis ofthe mold) toward and away from the first side wall. This brings theinner surface of the second side wall into and out of contact with theother longitudinal edge of the base wall to close and open the mold.

The height and longitudinal slope of the second side wall can beadjusted on the vertical rails of the framework by jack screws or othersuitable means. In this way, one side face of the resulting castconcrete barrier can be oriented relative to the other side face toconform to any misalignment in level and slope between the two adjacentroadways within a predetermined maximum vertical range.

One of the principal inventive features of the adjustable mold of thepresent invention is the design of the end closures. If the second sidewall must be adjusted to a non-horizontal position, the end edges of thesecond side wall will not be coplanar with the end edges of the firstside wall. This misalignment presents a difficult closure problem,particularly since the degree of misalignment can differ from section tosection.

The solution has been to provide an end closure that is split at thevertical center plane of the mold. A first half end plate is fixedlymounted on an upright end framework that is pivotally mounted to swingtoward and away from a respective end of the mold into and out ofsealing contact with the ends of the first side wall and the base wall.A second half end plate is supported on the end framework by suitablemeans such as a jack screw to permit adjustable vertical slidingmovement of the second half end plate in contact with the first endplate and with the inside vertical surfaces of the second side wall ofthe mold until the sloping surfaces of the second side wall are sealedby mating surfaces on the second half end plate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, in section, of a highway having aconventional asymmetric median barrier arranged between two lanes atdifferent grade levels.

FIG. 2 is a cross-sectional view of a conventional symmetric barrier.

FIG. 3 is a cross-sectional view of a conventional asymmetric barrier.

FIG. 4 is a perspective view of an adjustable mold apparatus for castingasymmetric concrete highway barriers.

FIG. 5 is a partial plan view, in section, taken along the line 5--5 inFIG. 8, of the adjustable mold apparatus of FIG. 4.

FIG. 6 is a side elevation view of the adjustable mold apparatus of FIG.4.

FIG. 7 is an end elevation view showing the adjustable mold apparatus ofFIG. 4 with the end door of the mold open and illustrating the verticaladjustment capability of the mold.

FIG. 8 is an end elevation view of the mold apparatus similar to FIG. 7but showing the end door shut.

FIG. 9 is a cross section view in elevation of the mold apparatus ofFIG. 4, taken along the line 9--9 of FIG. 6 and showing the pouring ofan asymmetric concrete barrier.

FIG. 10 is a plane view of the adjustable mold apparatus of FIG. 4.

FIG. 11 is a perspective view similar to FIG. 4 showing the adjustablemold apparatus with the end door opened prior to removing a curedconcrete barrier from the mold.

FIG. 12 is an end elevation view of the mold apparatus of FIG. 4 showingthe end door open and a cable attached to a cured concrete barrier readyto lift the barrier from the mold.

FIG. 13 is an end elevation view similar to FIG. 10 but showing theadjustable side wall swung away and the cured concrete barrier beinglifted out of the mold.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference initially to FIGS. 4-9, an adjustable mold apparatus 20for casting an elongated concrete barrier section consists generally ofa rectangular base frame 21 upon which is mounted a fixed supportstructure 22 for a stationary side portion 23 of the mold and a movablesupport structure 24 for an adjustable side portion 25 of the mold.

The base frame 21 is a lattice-like welded assembly of steel channelsforming outer side members 26, outer end members 27, and spacedintermediate pairs of cross members 28. The fixed support structure 22includes an inverted channel beam 29 carried on upright members 30 andextending longitudinally above the base frame as an elongated horizontalpedestal to which is attached a bottom plate 31 of the stationary sideportion of the mold (see FIGS. 7 and 9). The remainder of the stationaryportion of the mold includes an elongated rectangular steel plate,comprised of surfaces 31, 32, 33, 34, and 35, which is bent to theconfiguration shown to form a first profiled side wall 36 of the mold.This first side wall 36 is rigidly supported by the remainder of thefixed support structure, which includes an upright welded frame ofvertical box-section end studs 37 (see FIG. 9) welded at their lowerends to the cross members of the base frame and at their upper ends to alongitudinally extending box beam top header 38. Between the end studs,spaced transverse rib plates 39 are welded to the stationary side wallplate and to the header beam 38 to create a rigid supporting structurethat prevents the side walls from deflecting under the pressure ofconcrete poured into the mold.

A catwalk 40 supported by joists 41 welded to the rib plates 39 andenclosed by a guard rail 42 supported on stanchions 43 provides accessfor workmen to the top of the mold.

The movable portion of the mold similarly includes elongated rectangularsteel surfaces, 44, 45, 46, and 47, formed by bending a single elongatedplate to form a second profiled side wall 48 of the mold. Longitudinallyspaced vertical rib plates 49 welded top and bottom to horizontal boxbeams 50 and 51, respectively, provide a stiff grid-like backing for theplates of the movable side wall of the mold. Three vertically spacedlongitudinally extending horizontal beams 52, 53, and 54 (see FIG. 9)are welded to notches in the outside edge 55 of each rib plate. Thesebeams stiffen the movable side wall structure and also serve as elementsfor connecting the second side wall to longitudinally spaced uprightsupport posts 56.

Each support post 56 is mounted between a corresponding pair of crossmembers 28 on a bolt 57 which serves as a pivot pin for limited rotationin a vertical plane perpendicular to the longitudinal axis of the mold(see FIG. 9). A sleeve 58 loosely telescoped over each support post 56is fastened to each of the three horizontal beams 52, 53, and 54 byclamping means 59 such as pairs of studs 60 welded to the inner face 61of the sleeve 58 above and below each horizontal beam and carryingstraps 62 that press the corresponding horizontal beam against the innerface of the sleeve by means of nuts 63. The studs 60 of each pair arespaced apart by more than the vertical dimension of the correspondinghorizontal beam to permit a small amount of angular displacement (on theorder of 10 degrees) between the sleeve and the horizontal beams towhich it is clamped.

The height of the second side wall 48 of the mold can be adjusted byscrew jacks 64 located at each end of the mold structure (see FIGS.5-8). Each screw jack 64 includes a long T-handled screw 65 supported bya first nu 66 welded to the screw or otherwise fixed against rotationwith respect to the screw, and bearing on a top plate 67 of a firstbracket 68 that is welded to a side face 69 near the top of an endmostone of the support posts 56. The screw extends loosely through a hold inthe top plate 67 downward through a corresponding hole in a top plate ofa second bracket 71 welded to a side face near the upper end of thecorresponding sleeve 58. The screw is threaded through a second nut 72that is welded to or otherwise anchored against rotation with respect tothe under surface of the top plate 70 of the second bracket. By thisarrangement, rotation of the jack screw 65 by its T-handle, clockwise orcounterclockwise, will respectively raise or lower the correspondingsleeve 58 on its end support post 56.

Rotation of the jack screw 65 at one end of the mold structure can becoordinated with the rotation of the corresponding jack screw at theother end to maintain the second side of the mold level (as shown by thesolid lines in FIG. 6). Or the number of turns for each jack screw maybe different, so that the second side of the mold becomes tilted fromone end to the other (as shown by the dash-dot lines in FIG. 6). Asdescribed above, the clamping means for attaching the horizontal beamsof the second side of the mold to the sleeves 58 permits the necessaryangular adjustment to occur between the beams 52, 53, and 54 and thesleeves 58 if the side wall is tilted longitudinally.

As shown clearly in FIGS. 4, 5, 6, and 9, each sleeve 58 can bereleasably locked at any height to its respective support post 56 bythree T-handled clamping screws 73 that are threaded into nuts 74 weldedto an outer side wall of the sleeve in line with holes in the sleevewall to permit the inner end of the clamping screw to bear against theadjacent side wall of the corresponding support post 56.

In addition, the adjustable second side of the mold can be tiltedlaterally away from the stationary first side by means of two T-handledlateral adjustment screws 75, located one at each end of the movableside of the mold structure. Each lateral adjustment screw 75 is insertedloosely through a hole in a flat plate 76 welded to the outer face ofone of two stationary end posts 77. Each end post 77 has a lower endwelded to the corresponding transverse end member 27 of the base frame21 and is rigidly supported by a lateral brace 78 welded to a respectiveupright corner post 79 that is stiffened by an inclined prop 80. Eachlateral adjustment screw is threaded into a first nut 81 that is weldedor otherwise fixed to a bracket 82 made from a short length of steelchannel. Each bracket 82 is welded or otherwise fastened to the upperend of the corresponding endmost pivotable support post 56. A second nut82 is fixed to the lateral adjustment screw and bears against the outerface of plate 76, so that clockwise rotation of the T-handle will drawthe movable side of the mold away from the fixed side. This action isshown most clearly in FIGS. 12 and 13, which will be described infurther detail below in connection with the operation of the mold.

Conversely, tie rods 84 (see particularly FIG. 9) are used to draw andhold the adjustable second side of the mold tightly against thestationary first side. A tie rod 84 is provided between the top of eachpivoted support post 56 and a corresponding bracket 85 welded to the topheader 38 of the fixed support structure for the stationary wall. Eachtie rod 84 has a screw-threaded first end 86 and a second end 87provided with a hook 88 that engages a bolt or pin 89 extending betweentwo side plates 90 of a U-shaped support member 91 welded to the upperend of the corresponding support post 56. The screw-threaded first end86 of each tie rod rests in a slot 92 (FIG. 9) provided in the bracket85. A tubular T-handled nut 93 is screwed onto the first end of the tierod to bear against the bracket.

The movable side of the mold structure also has a catwalk 94 supportedon joints 95 that have inner ends welded to respective ones of the ribplates 49. The outer ends of the joists carry cylindrical sockets 96into which are inserted stanchions 97 that support a guard rail 98. Thissecond catwalk 94 provides access to the adjustable side of the mold andis at a convenient height to allow easy operation of screw jacks 64 andlateral adjustment screws 75 as well as easy access for finishing thetop of the concrete surface.

As mentioned earlier, an important feature of the present invention isthe arrangement for providing an adjustable closure for each end of themold. With reference particularly to FIGS. 4-8, first and second endclosures 101 and 102 (FIG. 5) are provided, one at each end of the mold.End closure 102 is essentially a mirror image of end closure 101; soonly the first end closure 101 will be described in detail.

Because the adjustable second wall of the mold can be tiltedlongitudinally as well as translated vertically, with respect to thestationary first wall, it is not possible to close the ends of the moldwith a flat plate butted against the end edges of the two walls of themold. As shown in FIG. 6, if the second wall is tilted, the end edges ofthe second wall (dot-dash lines) are no longer plumb and coplanar withthe corresponding end edges of the first wall. Since each end of thesecond side wall of the mold also can be shifted vertically with respectto the adjacent end of the first side wall of the mold, it also is notpossible to fit an end closure plate between the walls because theprofiled contours of the two side walls are infinitely changeable withrespect to each other.

The design of end closure 101 solves this problem by providing a closurepanel 103 in two sections carried by a door frame 104 that is swingablymounted on hinges 105 fastened to one of the box-section end studs 37 ofthe fixed support structure for the first side wall. The door frame is awelded assembly of two vertical box members 106 and 107 joined by anupper box rail 109. The door is extended laterally from box member 107by four cantilevered stub beams 110 supported at their free ends by avertical member 111 and a strut 112. The free end of each stub beam isfitted with a hinged eye latch 113 that engages a mating pin 114 on theadjacent stationary end post 77 to hold the door in the shut position.

A first rectangular end panel section 115 is fixedly attached to thedoor frame 104 adjacent to the hinges 105. A second end panel section116 abutting the first panel section is supported from the frame bymeans for providing vertical movement with respect to the first panelsection. The support means for the second panel section includes avertical box-section post 117 extending between the lower and upperrails 108 and 109. A sleeve member 118 is slidably mounted on post 117and is fixed to the second panel section 116.

A T-handled jack screw 119 connecting the upper rail 109 to a bracket120 fastened to the upper end of sleeve 118 provides vertical adjustmentof the second panel section with respect to the door frame (and thuswith respect to the first panel section) in the same manner as the jackscrews 65 provide vertical adjustment for the second side wall 48 of themold. After adjustment, the sleeve 118 can be locked to post 117 bythree T-handled clamping screws 121.

As shown most clearly by FIGS. 5 and 7, the first and second panelsections 115 and 116 have slidably abutting side edges 122 and 123 thatcontact each other on a vertical plane which is parallel to, andpreferably contains, the longitudinal center-line of the mold. The outerside edge 124 of the adjustable second panel section 116 has a profilethat mates with the profile of the inner surface of the second side wallof the mold. As mentioned previously, the first end panel section isrectangular, and it is sized to overlap the end edge of the stationaryfirst side wall of the mold as well as part of the end edge of thebottom plate of the mold. The hinges 105 are located relative to the endedge 125 of the stationary part of the mold so that the inner face offirst end panel section 115 abuts against the end edges of thestationary side wall plates 32-35 and the base plate 31 in sealingengagement therewith when the door frame 104 is latched shut.

The end edge 126 of the adjustable second side wall 48 of the moldextends beyond the plane of the end edge of the stationary part of themold (see FIG. 5) so that the end of the second side wall overlaps themating outer edge 124 of the second panel section 116. In this way, theprofiled side edge 124 of the second panel section seals against theinner surface of the second side wall 48 of the mold, while the face ofthe lower tail portion 127 (see FIG. 7) of the second panel sectionsealing abuts against the opposing portion of the end edge of the baseplate 31 of the mold.

The construction and operation of the second end closure 102 isidentical to that of the first end closure 101 except that the first andsecond end panel sections 128 and 129 and the door frame 130 of thesecond closure are mirror images of first and second end panel sections115 and 116 and door frame 104, respectively, of the first end closure101.

The procedure for setting up the mold, casting a concrete medianbarrier, and removing the barrier from the mold after curing will bedescribed next, with particular reference to FIGS. 6, 7, and 9-13.

First, the end doors are opened and all the tie rods 84 are loosened sothat the second end panel sections 116 and 129 of the two end panels canbe adjusted by rotation of the corresponding jack screws 119, asindicated by arrow C in FIG. 7, and the adjustable side wall 48 can befreely raised or lowered on the pivoted support posts 56 by rotation ofthe screw jacks 64 at each end of the mold, as indicated by the arrow Ain FIG. 7. The height of the top of the second end panel of therespective door at each end of the mold then will be adjusted inaccordance with predetermined difference in grade level between theroadway lanes adjacent to the two sides of the particular median barrierto be cast. This difference in grade level may change from one end ofthe barrier section to the other, so that the two second end panels maybe set at different heights relative to the tops of the fixed endpanels. After adjustment, the end doors are then shut and locked by theT-handled clamping screws 121, after first making sure that theadjustable side wall 48 is lowered sufficiently to avoid interferingwith the second end panels.

The top of adjustable side wall 48 (i.e., the upper surface of box beam50) defines the base of the barrier, since the mold is inverted. Thepurpose of the inversion is to locate the widest cross dimension at thetop of the mold. This permits better access to the concrete as it isbeing poured to insure that no pockets or voids are created and producesa smoother, more dense surface. The vertical dimension of the topmostside plate surface 47 of adjustable side wall 48 is equal to thepredetermined distance from the foundation for the barrier to a levelthree inches above the finished surface of the adjacent roadway. Thevertical dimension of the corresponding topmost plate surface 35 of thestationary side wall 36 is greater than the vertical dimension of platesurface 47 by an amount equal to the preselected vertical adjustmentcapacity of the mold, which may be two feet, to accommodate the maximumexpected grade level difference between adjacent roadways.

It will be noted that the vertical dimension of the lowermost side platesurface 44 of adjustable side wall 48 exceeds the vertical dimension oflowermost side plate surface 32 of stationary side wall 36 by anequivalent amount, again to accommodate the range of vertical adjustmentprovided by the mold assembly.

Next, each end of the adjustable side wall is raised by the respectivescrew jack until the ends fit snugly against the respective second endpanels of the end doors. After the height of each end of the adjustableside wall 48 has been set appropriately, the wall can be locked to theposts 56 by the clamping screws 73.

Fastened to the top of each of the second end panel sections is ahorizontal angle bar 131. This bar also extends across the face of theadjacent one of the fixed panel sections 115 and 128 but is not fastenedto the fixed section. Thus, the angle bar 131 rises up and down with thesecond end panel section 116 and 129. The top of the adjustable sidewall 48 will be set level with the base of the angle bar, and this baseserves as a shelf or rest for an elongated screed rail 132, made ofaluminum angle stock. A short screed is then used to even off thesurface of the poured concrete to provide a flat base for the finishedbarrier.

After the movable side wall is finally adjusted, the tie rods 84 areinstalled and tightened to bring the movable side wall 48 into sealingcontact with the edges of the base plate 31 and the second end panelsections 116 and 129. As shown in FIG. 9, reinforcing bars 133 are nextpositioned in the mold, and premixed concrete is poured into the moldfrom a bucket 134. The concrete in the mold is vibrated during pouringto eliminate air pockets, as is well known, and the top of the concreteis finished off by moving a screed across the mold on the angle bars 132and the top of side wall 48, as previously described.

With reference to FIG. 13, following an appropriate time for curing, themovable side wall 48 of the mold is then drawn away from the casting, inthe direction of arrow D, by rotating the T-handled screws 75, as shownby the arrow E. Then the end doors are unlatched and swung open, asindicated in FIGS. 10 and 11. Next, lifting lines 135 (set FIG. 12) arehooked to lifting inserts 136 that were placed in the concrete before itset, and a slight strain is taken on the lines. The casting can then belifted from the mold, in the direction of arrow F, without requiringexcessive force to pull the concrete away from the side walls of themold.

From the foregoing description, it will be apparent that the adjustablemold of the present invention permits easy and rapid set up for castingeither symmetric or asymmetric barriers and having a range of adjustmentcapable of meeting any requirement. The mold is rugged enough to have analmost indefinite service life with maintaining the cast products withinclose dimensional tolerances.

As previously pointed out, the split end panel arrangement is a keyfeature of the mold that allows a full range of height and tiltadjustment for the movable side wall of the mold while still assuringleak tight sealing at the ends of the mold without the need for anyextraneous gaskets or filler. In this connection, the tightness of theinterface between the two panel sections at each end can be augmented bymeans of a threaded stud 137 that extends laterally from the lowerportion of the vertical sleeve 118 (see FIG. 11). A cylindrical nut 138threaded onto the stud can be screwed out to bear against the verticaledge of member 107 of the door frame and thus close any gap that mayexist between the two panel sections. To prevent cement paste fromentering the joint between the panel sections, it is covered withmasking tape before each pour.

Although the preferred embodiment of the invention has been shown anddescribed, it will be appreciated that various other arrangements arepossible within the scope of the invention. In particular, manyalternative support structures can be used to provide strength andrigidity without adversely affecting the adjustability of the system.Also, the simple and inexpensive manually operated screw jacks used asthe adjusting means could be replaced by electrically or hydraulicallyactuated devices. Additionally, the end closures can be mountedotherwise than on hinges for rotation about a vertical axis. Forexample, the door frames could be pivotally supported like the movableside wall for rotation about a horizontal axis. Alternatively, either orboth of the movable side wall and the end closures could be supported onrails or other means for horizontal translation toward and away from thestationary parts of the mold. Many other modifications are also possiblewithin the scope of the appended claims, which define the invention.

It is possible, in addition, to change the mold so that the barriersection is poured right side up instead of upside down, but it is moredifficult to pour and vibrate the concrete to assure no voids and asmooth surface finish. Further, the movable side wall could be adjustedbefore the second end panels of the doors, but each second end panel hasan adjacent fixed panel that makes adjustment a matter of a single quickand accurate measurement. Further, the finished casting does not have tobe lifted completely clear of the mold but can be slipped out of one endafter being lifted away from contact with the bottom and fixed sidewall.

Finally, the stationary sidewall may also be mounted on hinged verticalsupports and be separate from the base plate, if desired, to make iteven easier to remove the cured casting from the mold. That isparticularly advantageous if the mold sides are provided with anembossed surface to give a textured effect to the barrier wall.

I claim:
 1. An adjustable mold for an elongated rectilinear concretemember, the mold comprising:a stationary portion including an elongatedhorizontal base wall and a first upright side wall, the base wall havingfirst and second longitudinal edges extending between a first end and asecond end of the base wall, and the first side wall having a first endand a second end; means for supporting the first side wall contiguous tothe first longitudinal edge of the base wall with the first and secondends of the first side wall being adjacent to the respective first andsecond ends of the base wall; a movable portion including an elongatedsecond side wall having a first end, a second end, and a transverseprofile having nonvertical portions; means for mounting the second sidewall upright and in abutting engagement with the second longitudinaledge of the base wall, the first end of the second side wall beingadjacent to the first end of the base wall and the second end of thesecond side wall being adjacent to the second end of the base wall;means for independently adjusting the heights of the first end and thesecond end of the second side wall with respect to the base wall; firstand second end walls, each end wall being formed with a first panelsection and a second panel section; means for adjusting the position ofthe second panel section relative to the first panel section of each endwall; and means for supporting the first and second end walls relativeto the respective first and second ends of the mold such that the firstpanel sections sealably engage the corresponding ends of the base walland the first side wall, and the second panel sections are adjustable tosealably engage the corresponding ends of the second side wall.
 2. Anadjustable mold according to claim 1 wherein the means for mounting thesecond side wall comprises means for moving the second side wall towardand away from the second longitudinal edge of the base wall.
 3. Anadjustable mold according to claim 1 wherein the means for mounting thesecond side wall comprises:a first upright post located adjacent to thefirst end of the second side wall; a second upright post locatedadjacent to the second end of the second side wall; means for hingedlysupporting the lower end of each post to permit limited rotation of thepost toward and away from the second longitudinal edge of the base wall;and means for slidably coupling the second side wall to the first andsecond upright posts.
 4. An adjustable mold according to claim 3 whereinthe means for independently adjusting the heights of the first end andthe second end of the second side wall with respect to the base wallcomprise:first jack means connected between the first upright post andthe means for slidably coupling the second side wall to the firstupright post; and second jack means connected between the second uprightpost and the means for slidably coupling the second side wall to thesecond upright post.
 5. An adjustable mold according to claim 4 whereinsaid first and second jack means comprise screw jacks.
 6. An adjustablemold according to claim 1 wherein each of the means for supporting thefirst and second end walls comprises:an upright frame, the first panelsection of the respective end wall having a straight edge and beingfixed to the frame such that said straight edge coincides with avertical plane that intersects the base wall of the mold when the firstpanel section sealably engages the corresponding ends of the base walland the first side wall, and the second panel section having a firstside with a straight edge and a second side, opposite the first side,with an edge conforming to the transverse profile of the second sidewall; means for hingedly mounting the frame on the stationary portion ofthe mold; means for slidably coupling the second panel section forvertical translation with the straight edge of the first side of thesecond panel section abutting the straight edge of the first panelsection; and means for adjusting the height of the second panel sectionwith respect to the frame so that the second side of the second panelsection mates with the profile of the second side wall of the mold. 7.An adjustable mold according to claim 6 wherein the means for hingedlymounting the frame on the stationary portion of the mold comprises meansfor rotating the frame about a vertical axis adjacent to thecorresponding end of the first side wall.
 8. An adjustable moldaccording to claim 6 wherein the first and second ends of the first sidewall lie in respective common planes with the first and second ends ofthe base wall, and the first panel sections of the respective end wallshave faces that sealably engage the corresponding ends of the base walland the first side wall in the respective common planes, and wherein thefirst and second ends of the second side wall extend beyond saidrespective common planes for mating with the edges of the second sidesof the respective panel sections.
 9. An adjustable mold according toclaim 1 wherein the nonvertical portions of the second side wall slopeupwardly away from the first side wall so that the cross dimension ofthe mold increases with increasing distance above the base wall.
 10. Amethod of forming an asymmetrical concrete barrier section forseparating highway surfaces of predetermined different elevations andgrades, the barrier section including oppositely disposed side wallshaving surfaces that extend obliquely upward and inward from a baseportion to a top surface narrower than the base portion, with theoblique side wall surfaces on each side arranged to be disposed atpredetermined equal heights above the respective adjacent highwaysurface, wherein the method comprises:providing an elongated mold havinga stationary first side wall including an oblique surface portion forforming the corresponding oblique surface of one side wall of thebarrier and a stationary bottom wall; an adjustable second side wallincluding an oblique surface portion for forming the correspondingoblique surface of the other side wall of the barrier; and two endwalls, each end wall being vertically split into a fixed height sectionand an adjustable height section and each adjustable height sectionhaving an oblique outer side edge matable with the oblique surfaceportion of the second side wall; adjusting the height of the adjustableheight section of each end wall to a predetermined value relative to theheight of the fixed height section corresponding to the predetermineddifference in elevation of the separated highway surfaces at therespective ends of the barrier section; placing each end wall so thatthe fixed height section is in sealing engagement with the bottom wallof the mold; placing the second side wall into sealing contact with thebottom wall of the form; adjusting the height of one end of the obliquesurface portion of the second side wall of the mold to mate with theadjacent edge of the adjustable height section of the respective endwall; adjusting the height of the opposite end of the oblique surfaceportion of the second side wall to make with the adjacent edge of theadjustable height section of the respective end wall; pouring a concretemixture into the form to a predetermined level above the obliquesurfaces of the side walls; and removing the poured barrier from themold after the concrete has set.
 11. A method according to claim 10, themethod further comprising:disposing the second sidewall close to but notin contact with the bottom wall of the mold prior to adjusting theheight of the adjustable height section of each end wall to provideclearance for adjusting said sections.
 12. A method according to claim10 wherein the step of removing the cured concrete barrier from the moldcomprises:moving the second side wall away from contact-with the bottomwall of the mold; moving the end walls away from contact with thecorresponding ends of the first side wall and of the bottom wall; andlifting the cured concrete barrier from the end. .Iadd.
 13. Anadjustable mold for an elongated rectilinear concrete member, the moldcomprising:a first portion including a first upright side wall having afirst end and a second end; an elongated horizontal base wall havingfirst and second longitudinal edges extending between a first end and asecond end of the base wall; means for supporting the first side wallcontiguous to the first longitudinal edge of the base wall with thefirst and second ends of the first side wall being adjacent to therespective first and second ends of the base wall; a second portionvertically movable with respect to the first portion and including anelongated second side wall having a first end, a second end, and atransverse profile having nonvertical portions; means for mounting thesecond side wall upright and in abutting engagement with the secondlongitudinal edge of the base wall, the first end of the second sidewall being adjacent to the first end of the base wall and the second endof the second side wall being adjacent to the second end of the basewall; means for independently adjusting the heights of the first end andthe second end of the second side wall with respect to the heights ofthe first end and the second end of the first side wall; first andsecond end walls, each end wall having a side edge profiled to mate withthe nonvertical portions of the second side wall; means for adjustingthe height of the profiled edge of each end wall to match the height ofthe second side wall; and means for supporting the first and second endwalls relative to the respective first and second ends of the mold suchthat the end walls sealably engage the corresponding ends of the basewall and the first side wall, and the profiled side edges of the endwalls are adjustable to sealably engage the transverse profile of thesecond side wall. .Iaddend. .Iadd.14. A method of forming anasymmetrical concrete barrier section for separating highway surfaces ofpredetermined different elevations and grades, the barrier sectionincluding oppositely disposed side walls having surfaces that extendobliquely upward and inward from a base portion to a top surfacenarrower than the base portion, with the oblique side wall surfaces oneach side arranged to be disposed at predetermined equal heights abovethe respective adjacent highway surface, wherein the method comprises:providing an elongated mold having a first side wall including anoblique surface portion forming the corresponding oblique surface of oneside wall of the barrier and a bottom wall; a second side walladjustable with respect to the first side wall and including an obliquesurface portion for forming the corresponding oblique surface of theother side wall of the barrier; and two end walls, each end wall havingan oblique outer side edge matable with the oblique surface portion ofthe second side wall; adjusting the height of the oblique outer sideedge of each end wall to a predetermined value relative to the height ofthe oblique surface of the first side wall corresponding to thepredetermined difference in elevation of the separated highway surfacesat the respective ends of the barrier section; placing each end wall sothat the end wall is in sealing engagement with the bottom wall of themold; placing the second side wall into sealing contact with the bottomwall of the mold; adjusting the height of one end of the oblique surfaceportion of the second side wall of the mold to mate with the adjacentoblique edge of the respective end wall; adjusting the height of theopposite end of the oblique surface portion of the second side wall tomate with the adjacent oblique edge of the respective end wall; pouringa concrete mixture into the form to a predetermined level above theoblique surfaces of the side walls; and removing the poured barrier fromthe mold after the concrete has set. .Iaddend.